Recycle shipping assembly

ABSTRACT

A cushioned shipping assembly includes a carton and foam inserts to support a product shipped by a supplier, which elements are successively returned by an end user to be reused in the same or other shipping assembly, while various components are recycled as they become spent. In some embodiments, the carton collapses to a diminished size for return. A resource center reroutes or refurbishes the components, recycling aged or spend pieces. On-premises pelletizing of reclaimed polymer provides a more efficient, environmentally clean system. Spent inserts of identified polymer may be diverted to users of specific resins.

RELATED APPLICATIONS

This is a continuation of application Ser. No. 08/461,045 filed on Jun.5, 1995, which is a continuation of Ser. No. 08/071,234, filed on Jun.2, 1993, now U.S. Pat. 5,456,061, which is a continuation of Ser. No.07/775,694, filed Oct. 10, 1991 (now U.S. Pat. No. 5,247,747), which isa CIP of 07/690,082, filed Apr. 23, 1991 (now U.S. Pat. No. 5,131,212),which is a CIP of 07/427,812, filed Oct. 26, 1989 (now abandoned).

BACKGROUND OF INVENTION

The present invention relates to packaging and shipping containers whichare adapted to a particular size or shape of a product or object, andare used to enclose and protect the object against shock duringshipment. In particular, it relates to such shipping containers whichinclude cushioning or inserts.

The invention also relates in general to methods and practices formaking up or fabricating such shipping containers and the ultimatedisposal of waste resulting therefrom.

Such containers are commonly used for the packaging or shipment ofmicrocomputers, CRT displays and workstations, as well as for delicateelectronic or optical instruments and like consumer goods. Thecushioning employed in the interior of a carton for these purposes mayconsist of foamed polymeric material in the form of broad sheets,rectangular blocks, or even of contoured molded foam which conforms tothe shape of the object being shipped, for example. The foam materialmay be selected to provide protection against impact and vibration,protection against crushing, or a combination of these properties, andit may be in the form of loose inserts or in the form of cushion memberspermanently affixed either to the carton or to protective support or capmembers that fit within the carton.

The aforesaid products generally have a container volume of up toseveral cubic feet, and the amount of cushioning involved in theirpackaging may be substantial. Where the product is an irregularly shapedobject, such as a console or work station, the complexity and cost ofthe shipping assembly itself can be significant. Nonetheless, almost allcontainers of this type are single-use containers, intended to bediscarded by the end user who receives the shipped product. The disposalof such packaging materials raises environmental concerns, and thenature of prior art packaging systems further renders it difficult toeffect such disposal in an environmentally sound manner.

Accordingly, it is desirable to provide a more efficient andenvironmentally sound cushioned shipping container. It is also desirableto provide a general method for making, using and ultimately disposingof shipping containers.

SUMMARY OF THE INVENTION

These ends are achieved in accordance with a method of the presentinvention by providing a shipping package assembly including an externalcarton and one or more cushioning inserts that define a product support.After shipment of a product in the assembly, the empty assembly with itsinserts, or portions thereof, is reshipped to the shipping packagefabricator or authorized third party who then inspects and refurbishesthe carton and the inserts to the extent necessary, and returns theassembly to the product manufacturer to ship another product. Thematerials employed for the carton and the cushioning inserts are eachpreferably adapted to withstand multiple uses, are selected to berecyclable, and are compatible with reprocessing of the other materialsin the assembly.

In a preferred embodiment of the assembly for this method of fabricationand reuse, the cushioning material is formed, for example, of apolymeric material such as polyethylene foam, plastic sheet materialencapsulating air pockets ("bubble wrap"), elastomeric films, inflatableplastic pieces or thermally insulating materials, such as foamedpolystyrene. The inserts can be attached or bonded to the carton by ahot-melt wax or other adhesive.

The carton can be formed of corrugated cardboard, for example, and thecardboard may be coated with a protective coating, such as aMichaelman-type or other coating to enhance its strength and resistanceto water and scuffing without impairing its suitability for repulping.Other materials suitable for use to form the carton include rigidplastics such as polystyrene, or polyvinyl chloride, foamed polymerssuch as polystyrene or polyurethane foams, metal and wood. The cartoncan be a reclosable plastic carton which can be reused several times andthe plastic material can be recycled after the useful life of thecarton.

In particular or further preferred embodiments, the carton is of atwo-piece or collapsible construction which attains a reduced size whenemptied of the product, so that, once the carton is emptied, the cartonand inserts may be returned to the fabricator in a smaller form.Advantageously, the carton is shipped by an alternate carrier, e.g., bya courier or by a consumer package deliver network such as UPS, whichwould not accept, or which would impose a rate penalty upon, the fullsize carton.

Preferably, the shipping assembly includes a prominent surface displayand a label window with appropriate legends to assure that the assemblyis routed in order to the product user and to the fabricator.

The invention also includes a method for the reclamation and reuse ofpost-consumer packaging materials. Preferably the packaging materialsallow multiple uses of each element.

In the practice for reshipping, inspecting and resupplying completedshipping assemblies, custom containers preferably contain anidentification code which specifies control data such as material typeand size specifications, manufacturer identity and relevant termsgoverning the quantity, delivery dates required by the product shipperand cost of refurbished containers.

Preferably, each complete container assembly is shipped with a returnlabel containing this code, which may be a freight prepaid labeldesignating a selected carrier or package delivery service that actsunder a contract to pick up and return used assemblies to the inspectionand refurbishment center.

In a most preferred embodiment, the containers or the cushioningelements thereof are returned to a resource center that performsnecessary inspection, and sorting and redirecting of elements orcomplete assemblies to their next destination. The resource centers arepreferably different from both original fabricators and themanufacturer, and are set up to sort and redirect plastic stock fromdifferent suppliers and to reship or replace inserts and assemblies ofdifferent product manufacturers.

In a still further preferred embodiment, the resource centers areregional centers, located at spacings such that they span the countryand such that each substantial user market lies close to a center withinthe bulk package delivery distance specified by the package carrier.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the invention will be understood from thefollowing detailed description, taken together with drawings ofillustrative embodiments, wherein

FIG. 1 is a block diagram of a method according to the invention;

FIG. 2 is a table of representative materials for the structuralelements contemplated for various embodiments of a cushioned shippingassembly according to the invention;

FIG. 3, is a perspective view of one embodiment of a carton which may beemployed in accordance with the invention;

FIG. 4 illustrates the carton of FIG. 3 in a collapsed state for returnto the fabricator;

FIG. 5 illustrates another embodiment of a shipping carton in Accordancewith the invention;

FIG. 6A, 6B illustrate one preferred set of internal components for thepractice of the invention with the cartons of FIGS. 3-5;

FIG. 7 illustrates different cushioning members for the practice ofaspects of the invention;

FIG. 8A, 8B are graphs showing representative shipping costs involved infreight return of packaging elements; and

FIG. 9 illustrates one network location of sorting centers for recyclingmulti-component packaging in accordance with a preferred method ofpracticing the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention relates to a method of providing a cushioned shippingassembly, including the steps wherein a packaging fabricator provides toa manufacturer or other user a carton with a plurality of cushioningmembers suitable for the user's product, and, after the assembly hasbeen used to ship the product to a purchaser or consumer, the carton andcushioning members, or a major portion thereof, is reshipped to a centerand the entire assembly is refurbished and reprocessed and/or reused. Atthe end of a useful lifetime, which may vary for different components ofthe system, each worn component is recycled. As will be described ingreater detail below, particular materials and constructions relatecooperatively to the different steps involved in reshipment, reuse andreclamation of materials to make the entire process economically andenvironmentally beneficial to the various persons providing or usingpackaging.

As shown in FIG. 1, the system 1 of the present invention includes apackaging system which is actively handled by different persons orbusinesses in succession. Initially at 2 the packing system, comprisinga carton and any special cushioning members, is assembled from a set ofmaterials such as corrugated panels, adhesives and bulk polymers.

The cushioning members can be, for example, made by a plasticsfabricator that typically will have facilities for molding plastic foamshapes, forming or shaping plastic sheets or blocks, or casting films.Alternatively, the inserts or cushioning material can be purchased froma supplier. she fabricator may have facilities for fabricating cartons,although these may be purchased separately. In the latter case thecompleted shipping assembly may be put together by an ultimate productshipper or OEM, from parts supplied from at least two sources, thefabricator and/or cushioning material supplier, and a carton supplier.

At 4, the fabricator then provides the shipping assemblies or elementsto an OEM, such as a manufacturer of computer terminals or the like, andat step 6 the OEM ships its product in the packaging to a distributor,end user or the like. At step 8, the emptied assembly is reshipped bythe end user to the fabricator or other entity, referred to below as aresource center, which performs a number of functions relating to theinspection, recycling or reuse of packaging material.

At this point, the method of providing and handling packaging differssubstantially from conventional practice, in that applicant provides acentral entity (fabricator or resource center) possessing data on thecarton and packaging inserts and that is responsible for routing thecartons and inserts.

In a presently preferred practice of the invention, discussed further inconnection with FIGS. 8A, 8B and 9, the return of used packaging iseffected via an intermediate step 8A wherein a data-coded shipping labelon the package, in conjunction with a contractual arrangement with aparcel delivery network, allows the end user to have the packagingpicked up and returned to a designated resource center without fillingout or attaching a further shipping label. This may be implemented inone embodiment by having a UPS or other carrier's label preaffixed tothe carton, together with a bar-coded identification that allows barcode readers to identify the shipment and print out a label, to routeand to invoice the shipment. In this manner, the sorting and return ofmaterials are more efficient. When the inserts of a package are made ofa particular polymer resin, the label or data coding preferably alsoidentifies the polymer, or directs the used assembly to a particularresource center that recycles that polymer resin.

Continuing with FIG. 1, at step 10 the fabricator/resource centerinspects and refurbishes the packaging assembly, reclaiming any spentmaterials for safe disposal or for recycling to a second use. At step12, as at step 4, the packaging system is again provided to the OEM.Conceptually, step 12 involves two substeps corresponding to thedifferent acts of refurbishing or recycling performed at step 10. In onesubstep, denoted 12a, the system is refurbished, which may involve oneor more of the original fabrication processing of step 2. In the othersubstep denoted 12b, the spent components are reclaimed and recycled.This involves separately and preferably reprocessing the components, oneexample being forming polyethylene sheet film products from spentpolyethylene foam material. The second use of a recycled component mayor may not be performed on-premises, and may either result in a productuseful as a shipping assembly component in step 2, or as a separateproduct for an external market. Thus, as indicated in the Figure, step12b may provide further materials to be used in step 2.

It should be noted that while the end user appears only at step 8 toreturn the packaging to the fabricator, in some embodiments the enduser's participation may be substantially greater. For example, whenused for shipping medical devices and supplies to a hospital, clinic, orresearch laboratory, where the receiving institution may be expected tohave waste segregation or processing protocols in effect, the presentsystem contemplates that such protocols may be utilized to segregatedand recycle or reship to the fabricator the used packaging assemblies orseparated components thereof. For such medical packaging it isunderstood that the reuse of components will further include the step ofsterilization of packaging for each transit.

Returning to FIG. 1, the first three steps of the method 2, 4, 6 areconventional. The remaining steps, when practiced according to theinvention as discussed further below, are environmentally beneficial andoffer benefits to each person. These steps involve the participation ofadditional persons in the system for its effectiveness. Certainpreferred construction features of the system as described more fullybelow render the performance of these additional steps convenient toachieve, economically beneficial or functionally self-effecting.

In accordance with the invention, the materials of construction for thecontainer system are selected from among materials which can beeffectively reclaimed after use and, preferably, recycled when wornbeyond reuse, by fabrication into the same, or new and differentproducts. Materials useful for forming the carton include wood-fiberbased products, e.g. paper or cardboard; metals; formable plastics,e.g., polyvinyl chloride; foamed polymers, e.g., polystyrene foam orpolyurethane foam; and wood. The carton is preferably corrugatedcardboard or plastic.

The cushioning inserts can be formed from a variety of materials basedupon the end use. Cushioning materials can include foamed material suchas polyurethane foam or polyethylene foams; plastic films, e.g.,elastomeric films; plastic sheets having plural entrapped air bubbles(conventionally referred to as "bubble wrap"); thermally insultingmaterials, such as polystyrene foam and other materials useful forpacking hot or cold materials e.g., dry ice; expanded mica("vermiculite"); foam "end caps", which are shaped articles of apolymeric foam the shape of which is specific for the object beingshipped; and inflatable plastic articles. All of the cushioningmaterials are selected so that they can be reused, reprocessed orrecycled.

In one embodiment of the present invention, bubble wrap made frompolyethylene sheets, or other plastic material, is used as thecushioning material in a container. Once the user has removed the objectfrom the carton, the carton containing the bubble wrap is picked up bythe parcel service and returned to the fabricator or third party.

In another embodiment of the invention, inflatable plastic bladders areused as cushioning material. In this embodiment, the shipping cartoncontaining plastic bladders in deflated condition are shipped to an OEM,who inflates the bladders with air according to his requirements. Theproduct to be shipped is packed in the carton and is cushioned by theinflated bladders. The product is shipped to the product user, who thendeflates the bladders, and returns them, preferably packed in theoriginal container, to the designated third party. The container and/orthe inflatable cushioning materials can be refurbished, if necessary,and reused or recycled. Alternatively, the carton can be disposedlocally, and the deflated bladders returned to the fabricator or thirdparty, for example, in a prepaid, preaddressed envelope or package.

Foams useful as cushioning materials preferably include foams whichprovide shock resistance without crushing, so that the cushion blocksperform effectively for at least several initial usages, and which alsomay be recycled into second-use products, such as films or denserextruded products. Preferably the cushion blocks are designed to survivemultiple shipping/storage cycles without falling below a specified levelof cushioning quality. This is achieved in part by providing larger"footing" or contact surfaces for a given product application, employinga lesser static loading value to determine the size of cushion blocksfor a particular product, and by compounding the foam to have relativelylonger-lived mechanical properties.

The material employed for the foam is preferably resilient and the stockpolymer material is not highly cross-linked. Suitable foams arepolyethylene foam, polypropylene foam, EVA and other polyolefin foams,and also copolymers thereof, among others. The cushioning elements alsoinclude non-attached loose fill cushioning, such as sheet foam andpellet material. The invention contemplates that the worn cushionmembers will generally be reprocessed by densifying the foam back intopellets of stock polymer, and that this material will be recycled,either at the fabricator, or elsewhere under contract, into film orother plastic product. It is contemplated that the adhesives used foradhering the board elements to the cushion blocks, or to cement folds ofthe carton upon itself, preferably include hot melt waxes, olefins orbonding materials that are compatible with the two principal packagingcomponents and with the processes involved in their recycling.

In one embodiment of the present invention, the container is fabricatedfrom a formable plastic material, such as polyvinylchloride sheets. Thecontainer can be fabricated by any known method for forming plasticshaped articles, such as stamping from a sheet with a dye, compressionmolding, vacuum forming, etc. The cushioning inserts in the containerare determined by the nature and configuration of the object to bepacked in the carton. The cushioning material can be elastomeric films,such as polyurethane films, for example, which suspend the object withinthe carton, or can be inflatable plastic bladders which are inflated forpacking and shipping and which can be subsequently deflated and returnedto the resource center as a much smaller package.

In accordance with a first preferred aspect of the invention, FIG. 2sets forth a table, by way of example, showing representative materialswhich may be used for cushioning, bonding, and carton coating in asystem for a corrugated cardboard or pulp-based packaging constructionin accordance with the present invention.

As shown in the Table, the invention contemplates that one or morecoatings or layers will be applied to a corrugated cardboard containerto implement the combination of recyclable elements thereof. These mayinclude coatings to strengthen the skin of the board, so that thecushioning, shipping labels and the like may be removed without damagingthe container and so that surface blemishes from impact are minimized,and also may include release coatings for labels, and waterproofingcoatings and scrubbable surface coatings to prevent the accumulation ofsoil on the carton in use. Suitable coatings include Michaelman coatingssuch as a Michaelman X-300, and other surface films and release coatingswhich do not impair the suitability of the board for repulping andreuse.

Within one or more of the above constructions, the inventioncontemplates that the return of the used assembly to the fabricator orresource center be facilitated or enhanced by providing a prominentgraphic display instructing the user how to return the container orcomponents thereof. For example, a block print legend is preferablyprinted under, or adjacent to, a removable invoice/label pocket, bearingthe legend

"THIS IS A (DEPOSIT-TYPE) RETURNABLE ENVIRONMENTAL RECYCLABLE CONTAINER.PLEASE DELIVER TO OR CALL UNITED PARCEL SERVICE TO PICK UP THISCONTAINER UNDER CONTRACT AXXXXX FOR RETURN TO XYZ FABRICATOR, CITY,STATE."

In the practice of the invention, it is contemplated that when used inconjunction with a manufacturer's ordering, shipping and productionsoftware systems, several different such legends may be automaticallyprinted out on labels which direct the return either to thefabricator/resource center (when reuse is contemplated), or to a localreclamation center (when the carton is configured for a product forwhich no further shipments are scheduled). The label preferably includesdata (such as a bar-coded number which may index a specification file)that identifies necessary information for routing, testing,refurbishing, reusing or scheduling delivery of the packaging elements.For example, the data may indicate the part number of an insert, theidentity and supply requirements schedule of an OEM that uses theinserts, and the material composition of the inserts. The data may alsoinclude an index to a file record that contains detailed contractinformation, such as the amount of credit allotted to a fabricator foreach returned insert, the schedule of charges to the OEM for each reusedinsert, and the like.

It will be appreciated that the system of the present invention achievesa significant efficiency of materials consumption since the reuse of thepackaging system even two or three times results in effectively using ahalf or a third as much material per transit; minor refurbishing offersgreater savings. The invention thus operates to reduce net consumption,as well as to recycle the used materials.

FIG. 3 illustrates one exemplary embodiment of the invention. A carton20 is formed of a bottom 22, a top 23 and preferably one or morecardboard inserts 24, 25. Bottom 22 is formed of a high strength doublewalled corrugated board, and, as illustrated, has the above-describedfabricator return freight legend 26 on an outer face thereof. Top 23 isformed of a lightweight material and forms a cap which telescopicallyslides over the bottom portion to form a closed box. Top 23, which mayhave a calendared, printed surface, is discarded after shipping, whilebottom 22 containing at least one of attached cushioning 27 and separateattached cushion blocks (not shown) is closed and reshipped to thefabricator after use. Arrows "s" and "e" indicate that the sides andends form flaps, which fold down along score lines 28, to close thecarton into a diminished volume for return. A top sheet 25, which mayalso have an attached cushion block and which is also returned with thebottom half 22, normally fits over the bottom 22, and may serve both toprevent the flaps from folding inward, and to provide additional wallstrength and protection for the top face. An inner sleeve 24 may also beprovided, after the first use and creasing of the flaps of bottom 22, toprevent folding in of the upper sides which have previously served asflaps.

FIG. 4 shows the portion of the assembly 20 consisting of bottom 22 andone or more of cushions 27, unattended blocks and inserts 25, foldedinto a closed position for return. In this position the combinedexternal dimensions of the carton assembly are reduced to be less than108 running inches or such other limit imposed by a parcel service, suchas the federal postal service or United Parcel Service, so that thecontainer may be economically returned, by single units rather thantruckload lots, to the fabricator. It will be understood that when theproduct to be shipped fits in a packaging assembly that already meetsthe dimensional requirements of the parcel carrier, the use of the folddown carton of FIGS. 3,4 is optional, or if used, the assembly may bereturned in its original full size configuration, without folding down.

The significance of the telescoping or collapsible carton will be betterappreciated with reference to FIGS. 8A and 8B. These Figures are chartsof shipping costs of packages, in dollars, for shipments by private UPScarrier (FIG. 8A) and by US postal service fourth class (FIG. 8B). Asclearly shown in these rate charts, costs escalate not only with packageweight, but also with distance shipped as measured in zones traversed.For UPS shipments, packages having a combined length plus girth greaterthan a seven foot threshold are automatically charged at the highest,twenty-five pound, rate even if the package in fact weighs only severalpounds. This results in a two-to-six-fold cost increase. Similarly, forUS postal rates, a "non-machinable surcharge" increases the rate forpackages of a size above a threshold that precludes passage through theautomated handling systems of the postal service.

Thus, in embodiments like that of FIGS. 3, 4 the degree of compacting ofthe returnable carton preferably is selected to bring the return cartonto a size below the threshold associated with these rate penalties, andto assure that the ratio of returned element value to the cost ofreturning those elements is as low as possible.

In one further embodiment of this aspect of the inventions, this isaccomplished by providing a return sack or envelope rather than acarton. Upon receipt by the user, the polymer inserts are removed fromthe board elements of the carton, and the inserts from one or more unitsare placed in a return-labeled sack or envelope for delivery to thefabricator/resource center. The pulp-based board elements are thenrecycled or otherwise disposed of locally, while the inserts arefreighted to be centrally sorted, recycled or reused. In this manner,the weight of returned components is minimized, and the low valuelocally recyclable board components are not needlessly shipped vastdistances.

FIG. 5 illustrates elements of another embodiment of the invention. Inthis embodiment, a pulp-based or cardboard carton 30 is provided havinga length L, width W and height H1 , with creases 32 at height H1defining two pairs of opposed flaps for closing the carton. The verticaledges of the box are cut, i.e., slotted at 34, down to a lesser heightH2 , and horizontal score lines 36 are provided at height H2 whichextend around the box so that after use the flaps 35a. . . 35d may becreased at the score lines 36 and folded down to provide a smallershipping carton of diminished height H2 . With normal half-width orhalf-length flap geometries for the original flaps 35a. . . 35d, thereduction in height achieved by this embodiment for the return containeris up to one-half of the length or width of the carton. Preferable,after this carton has been once used and return, on subsequent uses aninner sleeve 38 of height H1 fits within the full-height carton toreinforce the walls for again shipping a product. The sleeve is thenremoved when it is again desired to return the carton in its reducedsize.

FIGS. 6A, 6B illustrate a cushioning member 40 of the typeconventionally known as an end-cap, designed with particular suitabilityfor the practice of this invention. Cushioning member 40 is illustratedas comprised of an annular board of support plate 41 and several cushionblocks 42 of substantial thickness which extend across the full width ofthe plate. Plate 41 may be formed of thick cardboard and dimensionssubstantially in the illustrated proportions, to support and position aproduct assembly within a like-dimensioned rectangular carton, or it maybe formed of foam sheet stock like that of the blocks 42, therebyproviding both a positioning and an additional shock-absorbing function.The cushion blocks 42 may face inwardly against a packaged product, toprovide a product-cushioning as well as product-positioning function, ormay face outward toward the carton wall, thus providing only acushioning function. In any event, the cushion blocks 42 and the plate41 are preferable assembled of elementary slab material.

For particular utility with this invention, the plate of foam slab 41illustrated in FIGS. 6A, 6B is formed with a notch 43 at each cornersuch that the portion 44 of the plate protruding beyond the block 42fits within the central opening 45 of the opposite plate 41. With thisarrangement, a pair of cushioning members 40 may be shipped ascushioning end cap members within a container according to theinvention, and when it is desired to return the container, the twomembers may be crossed, as illustrated in FIG. 6B. This recesses onemember within the other, while providing a full-width verticallyextending structure that extends between the opposed top and bottomsides of the carton and stiffens the empty carton against collapse.

FIG. 7 illustrates another suitable form of cushion insert assembly 50for the practice of this invention. In this embodiment, a first member52 formed of a foam sheet 51a and cross slabs 51b provides one end cap,and a second member 54 formed of a foam sheet 53a and cross slabs 53bprovides another end cap. The cross slabs 51b 5are offset from the slabs53b so that they interfit between each other when the product is removedand members 52, 54 are placed on each other in the emptied carton,thereby reducing the dimension required for return of the cushioningmembers to less than twice the height of a single cap. Other end capconstructions of a more conventional type, such as a so-called slug capor a so-called picture frame, with the projection of one sized to fitwithin the recess of the other, are also contemplated within thepractice of the invention. In each case the foam material preferably hasthe reuse, longevity or other beneficial properties described above.

Returning to FIGS. 8A, 8B, it will be seen that the cost of returninserts or cartons rises with increasing distance. For UPS shipments,the increase can be a several-fold increase for a transcontinentalshipment, over the cost of shipping several hundred miles. For US postalshipments, a greater increase affects larger shipments. As describedabove, these costs are avoided in part by assuring that size thresholdsare not exceeded, and in part by restricting the reshipment of largerassemblies to separate cushion inserts and relying on local handling ofthe pulp-based components.

In accordance with a further embodiment of the present invention, aneffective reuse and recycling system is obtained by providing resourcecenters at plural locations located within two or fewer freight zones ofmajor metropolitan areas. The centers provide a network such that eachregion of the nation is served by a center lying within its low-freightrate territory. As shown in FIG. 9, a half dozen such centers, indicatedby markers 100, provide an effective set of collection points forreceiving, sorting, and redirecting used packaging and assemblies.

In this regard, applicant contemplates that the returnable packagingassemblies according to the present invention preferably includelabeling that automatically routes the returns to the nearest suchcenter. One implementation is achieved by providing a bar-coded shippinglabel, similar to the coding used to indicate corporate account numbersor destinations on existing courier labels, on the assembly shipped tothe end user. When the parcel service picks up the used assembly, theparcel service "reads" the code and acts in accordance with a previouslyarranged contract to insert the nearest resource center address. Inother embodiments, the code may indicate a particular fabricator that isresponsible for receiving and reusing or recycling all of that type ofassembly. In still other embodiments, the appropriate resource centermay be determined at the time that the OEM ships the product to an enduser, based on the location of the end user. In that case, the OEMprovides a label with the address of the particular resource center, sothat neither the end user nor the parcel service need perform any actsbeyond arranging for pick up of the parcel for return. Alternatively,the end user may be provided with a set of peel-off address labels, ofwhich the user selects and attaches the address of the nearest resourcecenter.

Advantageously, the coded information included on the label may includea part number or contract number which identifies the elements, suchthat the resource center may perform billing, accounting and otherfunctions, as well as identify the type of foam to control the purity ofrecycled resin from the sorting process.

For example, the identifier number can permit retrieval of file datathat gives the OEM a specified credit for a returned item, that directsthe shipment of inserts back to a particular OEM location at a reusediscounted price, or that gives a reuse commission to the originalfabricator when an element is sent out in a second packaging assembly.Similarly, the identifier may specify the precise resin employed in theinsert and may indicate a fabricator or a resin supplier that hasaccepted responsibility for recycling or disposing of spent inserts.

The method and system of exemplary embodiments of the invention beingthus described, variations and modifications will occur to those skilledin the art, and all such variations and modifications embodying theteachings in this disclosure, are considered to be within the scope ofthe invention, as set forth in the claims appended hereto.

We claim:
 1. A process for recycling or reusing a shipping containercontaining a plastic product support, said process comprising:(a)providing to a product provider a shipping container adapted to containa product for shipping to a customer, wherein said product is supportedby a plastic product support; (b) providing said customer withdirections for returning said shipping container and plastic productsupport to a third party refurbisher; (c) after removal of said product,returning said shipping container and plastic product support to saidthird party refurbisher pursuant to said directions; (d) reusing saidshipping container if said shipping container is reusable, refurbishingsaid shipping container and plastic product support if said shippingcontainer and plastic product support is refurbishable, or recyclingsaid shipping container or plastic product support if said shippingcontainer and plastic product support are not reusable or refurbishable;and (e) repeating steps (a), (b), (c) and (d).
 2. The process of claim 1wherein said directions are provided with said product sent to saidcustomer.
 3. The process of claim 1 wherein said shipping container isreturned to the refurbisher by a transport service.
 4. The process ofclaim 18 wherein step (b) comprises providing the customer withdirections for returning only said inner plastic product supports tosaid third party refurbisher and wherein only said inner plastic productsupports are returned to said third party refurbisher in step (c).
 5. Aprocess for reusing or recycling a plastic product support,comprising:(a) sending to a customer a product supported by a plasticproduct support; (b) providing said customer with directions forreturning said plastic product support to a third party refurbisher; (c)after removal of said product, returning said plastic product support tosaid third party refurbisher pursuant to said directions; (d) inspectingsaid plastic product support; (e) reusing said plastic product supportif said support is reusable, refurbishing said plastic product supportif said plastic product support is refurbishable, or recycling saidplastic product support if said plastic product support is not reusableor refurbishable; and (f) repeating steps (a), (b), (c), (d) and (e). 6.The process of claim 5 wherein the plastic product support comprises aplastic tray.
 7. A process for recycling or reusing a shippingcontainer, comprising:(a) providing a recyclable or reusable shippingcontainer to a product provider wherein said product provider can shipsaid shipping container having a product disposed therein to a customer;(b) providing said customer with directions for returning said shippingcontainer to a third party refurbisher; (c) after removal of saidproduct, returning said shipping container to said third partyrefurbisher pursuant to said directions; (d) inspecting said shippingcontainer; (e) reusing said shipping container or refurbishing saidshipping container if said shipping container is refurbishable andrecycling said shipping container if said shipping container cannot bereused or refurbished; and (f) repeating steps (a), (b), (c) (d) and(e).
 8. The process of claim 7 wherein said shipping container isreturned to said third party refurbisher by a transport service.
 9. Theprocess of claim 8 wherein said transport service is a parcel service.10. The process of claim 7 wherein said shipping container comprises anouter container and inner product supports.
 11. The process of claim 10wherein step (b) comprises providing the customer with directions forreturning only said inner product supports to said third partyrefurbisher, and wherein only said inner product supports are returnedto said third party refurbisher in step (c).
 12. The process of claim 7wherein said directions are provided with said product sent to saidcustomer.